Foam pillows

ABSTRACT

An improved foam pillow including multiple foam layers, with one or more of the layers including multiple channels designed to reduce the firmness of the layer, as well as enhance cooling air flow through the pillow, thereby increasing comfort to the user by approximating the feel of a down pillow. In some examples, the improved foam pillow includes a single unified top layer equipped with channels running through its center, and optional additional layers for height adjustment. In some further examples, the improved foam pillow includes multiple layers made from different types of foam to achieve cost savings. In still further examples, channels are provided in multiple layers to maintain a desired comfort and feel.

BACKGROUND

The present disclosure relates generally to comfort pillows. In particular, pillows constructed out of various types of foam that can be adjusted for height and firmness are described.

Known pillows are not entirely satisfactory for the range of applications in which they are employed. For example, existing pillows made from duck or goose down, while often being preferable in terms of comfort, have a tendency to flatten over the course of use, despite repeated fluffing. This flattening can result in an awkward head angle and less-than-optimal sleep for the user. Moreover, down pillows are unsuitable for some people who have an allergy to the associated dander. Existing foam pillows, while mitigating issues of allergies and flattening, often are relatively firm when compared to a down pillow and can have a tendency to trap heat, and thus are less comfortable to use compared to a down pillow. In addition, conventional pillows are not easily adjustable for height. This can discourage a user from bringing his or her pillow along while traveling where the firmness and quality of provided bedding is unknown, potentially resulting in poorer sleep quality.

Thus, there exists a need for foam pillows that improve upon and advance the design of known pillows. Examples of new and useful foam pillows relevant to the needs existing in the field are discussed below.

SUMMARY

The present disclosure is directed to an improved foam pillow. A pillow constructed from multiple foam layers is disclosed, with one or more of the layers including multiple channels designed to reduce the firmness of the layer, as well as enhance cooling air flow through the pillow, thereby increasing comfort to the user and preferably approximating the feel of a down pillow. By using channels in at least one layer to adjust the pillow's firmness in combination with careful selection of foam type for each layer, the improved foam pillow can be tailored to a wide variety of user preferences for comfort and cooling.

In some examples, the improved foam pillow includes a top layer made of memory foam with the second layer made of lower cost low density foam, to enable a cost savings. At least the second layer has channels for firmness adjustment and cooling. Additional layers can be optionally added to adjust the overall pillow height without substantially altering the pillow's firmness. The shape and number of the channels can be varied to achieve different firmness levels and comfort feels.

In still further examples, the top and second layers can be combined into a single unified layer, preferably made of memory foam, and including a series of channels through the center to adjust for desired firmness and enhance cooling.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a first example of an improved foam pillow.

FIG. 2 is an exploded view of the improved foam pillow shown in FIG. 1 depicting the various layers, including optional layers.

FIGS. 3A-3C are perspective views of the middle layer of the improved foam pillow shown in FIGS. 1 and 2, demonstrating various optional patterns.

FIG. 4 is a perspective view of a second example of an improved foam pillow including an integrated top and middle layer.

DETAILED DESCRIPTION

The disclosed improved foam pillows will become better understood through review of the following detailed description in conjunction with the figures. The detailed description and figures provide merely examples of the various inventions described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered without departing from the scope of the inventions described herein. Many variations are contemplated for different applications and design considerations; however, for the sake of brevity, each and every contemplated variation is not individually described in the following detailed description.

Throughout the following detailed description, examples of various improved foam pillows are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in each example. Instead, the use of related feature names will cue the reader that the feature with a related feature name may be similar to the related feature in an example explained previously. Features specific to a given example will be described in that particular example. The reader should understand that a given feature need not be the same or similar to the specific portrayal of a related feature in any given figure or example.

The disclosed improved foam pillow comprises a multiple-layer system, with one or more of the foam layers specially cut to adjust the firmness of the pillow as a whole, while enhancing airflow through the pillow and associated cooling. These improvements allow the pillow to better approximate the feel of a down pillow, while avoiding the problems with long-term flattening and providing a pillow that is usable by people otherwise allergic to down. Furthermore, by employing a layered system, the height of the pillow can be easily adjusted to accommodate a variety of users and bedding scenarios without significantly affecting the pillow's overall feel. Moreover, by changing layers the pillow's feel can be altered to suit different users, or changing needs of a user.

With reference to FIGS. 1-3C, a first example of an improved foam pillow, pillow 100, will now be described. Pillow 100 includes a first top foam layer 110, a second foam layer 120 that possesses a series of channels 130, and one or more optional bottom foam layers 140. In other examples, the improved foam pillow includes additional or alternative features, such as a single top foam layer that combines the top foam layer 100 with second foam layer 120 and the associated channels 130, as will be described later with reference to FIG. 4.

First top foam layer 110 is preferably manufactured from viscoelastic polyurethane foam, commonly referred to as memory foam, which is an open-cell type of foam that temporarily molds to user's contours, and is commonly used in bedding applications. Because of these properties, it is ideal for use in the top layer, the top surface of which directly cradles the user, providing initial comfort that approximates that of a down pillow. This foam is typically formed into the desired shape by injection molding. Alternatively, the top foam layer 110 can be constructed from other types of malleable synthetic or natural foam such as latex, gel cushioning, or any foam or other material now known or later devised that provides cradling properties for a user. First top foam layer 110 can optionally have a plurality of vertical channels 137, with each channel having an opening on the top and bottom surfaces of the first top foam layer 110. This enables air to flow through the first top foam layer 110 and, in conjunction with channels 130 that are located on the top surface of the middle second foam layer 120 (described below), enhances cooling air flow through the pillow. Preferably the vertical channels 137 are arranged so that at least some or all of the openings of each of the vertical channels 137 on the bottom surface of first top foam layer 110 are positioned over one of the channels 130, facilitating air flow between the vertical channels 137 and channels 130.

In the example shown in FIGS. 1 and 2, middle second foam layer 120 is preferably constructed from low density polyurethane foam, as typically employed in prior art foam pillows and many seat cushions. Using low density polyurethane foam for second foam layer 120 can result in a cost savings over use of memory foam as with top foam layer 110; however, the second foam layer 120 can also be constructed of memory foam if appropriate to achieve the desired pillow firmness. Likewise, second foam layer 120 can be constructed from other types of malleable synthetic or natural foam such as latex, gel cushioning, or any foam or other material now known or later devised that provides cradling properties for a user. As suggested above, second foam layer 120 may be made from different, or the same, material as top foam layer 110. As seen in FIGS. 1 and 2, the top surface of middle second foam layer 120 is in contact with the bottom surface of top foam layer 110.

Channels 130 are cut into the top surface of second foam layer 120 to both adjust the firmness of second foam layer 120, and to optionally enhance air flow through the pillow, so as to reduce the trapping of body heat by the pillow, thereby enhancing the user's comfort. The depth, number, and shape of the channels 130 can be varied to increase or decrease the desired firmness of the pillow and effective cooling. Deeper channels 130 that are kept relatively narrow will tend to increase cooling while not substantially reducing pillow firmness, while wider and deeper channels 130 can decrease firmness while increasing cooling. Conversely, shallower channels 130 will reduce effective cooling while not substantially altering pillow firmness. The positioning of channels 130 preferably is coordinated with the position of vertical channels 137, if present on the first top foam layer 110. The width, depth, and number of channels 130 selected also depend upon the types of foam employed for first top foam layer 110 and second foam layer 120. Where firmer, denser foams are utilized, the depth, width, and number of channels 130 employed will need to be increased to reduce overall firmness of pillow 100. Conversely, use of less dense foams with greater give will require fewer and shallower/narrower channels 130. By careful selection of the types of foam utilized as well as the shape and number of channels 130 employed, pillow 100 can be tailored to a wide variety of feels and firmness levels depending on user preference.

As can be seen in FIG. 2, top foam layer 110 can also optionally include channels 135 which are cut into the bottom surface of top foam layer 110, placed adjacent to the top surface of second foam layer 120. The implementation of channels 135 has the same considerations as described above for channels 130. Preferably, channels 135 will present a differing interfering pattern when disposed adjacent to channels 130, so as to prevent intermeshing of the channels 130 and 135, which would result in a reduction of effectiveness of the channels 130 and 135, causing the pillow 100 to gain potentially undesirable firmness and lose effective cooling.

Shown in FIGS. 3A to 3C are possible variants of the configuration of channels 130 and 135, depicted on second foam layer 120. It should be understood by a person skilled in the relevant art that the variations can also be applied to channels 135 located on the top foam layer 110. FIG. 3A depicts channels 130 with a square profile, as contrasted to the curved configuration shown in FIGS. 1 and 2. FIG. 3B depicts a concentric pattern, which may result in a somewhat warmer pillow near the center due to inner channels not having access to external air flow. FIG. 3C depicts channels 130 in an “egg crate” pattern configuration. It will be appreciated by a person skilled in the relevant art that the channels may be varied in size and configuration on a single layer, e.g. channels near the center of the layer are deeper and wider than channels near the outer edges, to achieve varying levels of firmness and comfort across the face of a pillow. Moreover, the disclosed pillow 100 should not be understood to be limited to the depicted channel 130 configurations; further variations such as a radial channel configuration, chevron pattern, or grid pattern, to list several further examples, are possible.

FIGS. 1 and 2 depict a bottom layer 140, which is preferably constructed of low density polyurethane foam. Bottom layer 140 is optional, and can be inserted or removed to adjust the overall height of the pillow 100. As shown in FIG. 2, multiple bottom layers 140 may be inserted as necessary to achieve a desired height and comfort. Bottom foam layers 140 can also be constructed of memory foam if appropriate to achieve the desired pillow firmness. Likewise, bottom foam layers 140 can be constructed from other types of malleable synthetic or natural foam such as latex, gel cushioning, or any foam or other material now known or later devised that provides cradling properties for a user. Bottom foam layers 140 may be made from different, or the same, material as top foam layer 110 or second foam layer 120. Furthermore, where multiple bottom foam layers 140 are employed, they may be made from different, or the same, material as each other.

It will be appreciated that the layered construction of pillow 100 allows for the swapping of top foam layer 110 or second foam layer 120 for layers constructed from different foam types, or with different configurations of channels 130. For top foam layer 110, the layer can additionally be swapped for a layer that either possesses or lacks channels 135. By swapping layers, pillow 100 can be adjusted over time for changing user needs, or layers can be replaced as they may wear out without the need for complete pillow replacement.

Turning attention to FIG. 4, a second example of a pillow 400 will now be described. Pillow 400 includes many similar or identical features to pillow 100. Thus, for the sake of brevity, each feature of pillow 400 will not be redundantly explained. Rather, key distinctions between pillow 400 and pillow 100 will be described in detail and the reader should reference the discussion above for features substantially similar between the two pillows.

As can be seen in FIG. 4, pillow 400 includes a top foam layer 410, and one or more optional bottom foam layers 430. Top foam layer 410 further has channels 420 for cooling and firmness adjustment. As can be observed in FIG. 4, top foam layer 410 merges the top foam layer 110 and second foam layer 120 into a single layer. Channels 420 serve the same purpose as channels 130 and 135 in pillow 100. As with channels 130 and 135, the configuration of channels 420 may be varied as depicted in FIGS. 3A to 3C, and as described above in the associated detailed description, to achieve the desired level of comfort and cooling.

Top foam layer 410, similar to top foam layer 110, is preferably constructed from memory foam, with the channels 420 implemented during the molding process. However, top foam layer 410 can also be constructed from other types of malleable synthetic or natural foam such as latex, gel cushioning, or any foam or other material now known or later devised that provides cradling properties for a user. Bottom foam layers 430 correspond in implementation and function to bottom foam layers 140 previously described.

The disclosure above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in a particular form, the specific embodiments disclosed and illustrated above are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed above and inherent to those skilled in the art pertaining to such inventions. Where the disclosure or subsequently filed claims recite “a” element, “a first” element, or any such equivalent term, the disclosure or claims should be understood to incorporate one or more such elements, neither requiring nor excluding two or more such elements.

Applicant(s) reserves the right to submit claims directed to combinations and subcombinations of the disclosed inventions that are believed to be novel and non-obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of those claims or presentation of new claims in the present application or in a related application. Such amended or new claims, whether they are directed to the same invention or a different invention and whether they are different, broader, narrower or equal in scope to the original claims, are to be considered within the subject matter of the inventions described herein. 

1. A pillow, comprising: a first layer of foam possessing a top surface and a bottom surface; and a second layer of foam with a top surface and a bottom surface, disposed so that the top surface is beneath and in contact with the bottom surface the first layer of foam, and the top surface of the second layer possesses a plurality of channels.
 2. The pillow of claim 1, further comprising one or more layers of foam possessing a top surface and a bottom surface, disposed so that the top surface of one of the one or more layers is beneath and in contact with the bottom surface of the second layer of foam, and any additional layers of the one or more layers are disposed below the one of the one or more layers that is in contact with the bottom surface of the second layer of foam.
 3. The pillow of claim 1, wherein the first layer and second layer are made from different types of foam.
 4. The pillow of claim 3, wherein the first layer of foam is made from memory foam.
 5. The pillow of claim 1, wherein the channels on the top surface of the second layer are shaped and arranged so as to allow air to flow through the pillow.
 6. The pillow of claim 1, wherein the bottom surface of the first layer of foam possesses a plurality of channels.
 7. The pillow of claim 6, wherein the channels on the bottom surface of the first layer of foam and on the top surface of the second layer of foam are shaped and arranged so as to allow air to flow through the pillow.
 8. The pillow of claim 1, wherein the first layer of foam possesses a plurality of vertical channels disposed so that each of said vertical channels runs between the top surface and the bottom surface of the first layer of foam.
 9. The pillow of claim 8, wherein the first layer of foam is approximately two inches to four inches in height.
 10. The pillow of claim 9, wherein the second layer of foam is approximately one to three inches in height.
 11. A foam pillow, comprising: a foam layer constructed of memory foam and possessing a plurality of channels running through the center of the foam layer so as to facilitate a flow of air, the foam layer sized so as to fit within a standard-sized pillowcase and being approximately four to six inches in height.
 12. The foam pillow of claim 11, further comprising one or more additional foam layers disposed below the memory foam layer.
 13. The foam pillow of claim 12, wherein the one or more additional foam layers are constructed of a different type of foam than the memory foam layer.
 14. A foam pillow, comprising: a first layer of foam possessing a top and a bottom surface; and a second layer of foam possessing a top and a bottom surface, disposed so that the top surface of the second layer is in contact with the bottom surface of the first layer of foam, and possessing a pattern imprinted upon the top surface of the second layer.
 15. The foam pillow of claim 14, further comprising one or more additional foam layers disposed below the bottom surface of the second layer.
 16. The foam pillow of claim 14, wherein the pattern imprinted upon the top surface of the second layer of foam reduces the overall firmness of the pillow.
 17. The foam pillow of claim 16, wherein the first layer of foam possesses a pattern imprinted upon its bottom surface, the pattern reducing the overall firmness of the pillow and designed to complement the pattern imprinted upon the top surface of the second layer of foam.
 18. The foam pillow of claim 14, wherein the overall height of the combined first layer and second layer is roughly between four to six inches.
 19. The foam pillow of claim 14, wherein the pattern imprinted upon the top surface of the second layer of foam is comprised of concentric circles formed by alternating peaks and troughs.
 20. The foam pillow of claim 14, wherein the pattern imprinted upon the top surface of the second layer of foam is an egg crate pattern. 